Food winding apparatus and system

ABSTRACT

A food winding apparatus, system, and method of forming a rolled food item utilizing a slotted spool or cup and a push plate to eject the rolled food item from the spool. A food winding unit utilizes a motor to rotate a slotted spool. The leading end of a supported strip of food is detected by a sensor and directed into the slot of a spool. A micro-controller triggers a motor in response to the sensor signal to rotate and form a rolled food item after a predetermined number of rotations. An actuator is activated to displace an ejection plate to eject the rolled food item from the slotted spool. The winding unit can be integrated into a system including an extruder to deposit food onto support strips, a series of conveyors, and a rotary knife to cut the supported strip of food into predetermined lengths suitable for being rolled into a food item by the winding unit.

FIELD OF THE INVENTION

The present invention relates to the production of food items, and moreparticularly, to an apparatus, system and method for manufacturing arolled food item utilizing a slotted spool which rotates to form therolled food item and pushing or ejecting the rolled food item from theslotted spool.

DESCRIPTION OF RELATED ART

Various types of food items have been manufactured using differentwinding or shaping mechanisms and techniques.

For example, some systems have formed a rolled food item by winding astrip of food upon itself. More specifically, the strip of food isdirected to one or more rollers which rotate in op directions to causethe leading end of the strip to fold upon itself. With the continuingrotation of the roller(s), a loosely rolled food item is formed.

Other conventional techniques utilize a series compression or formingrollers to form a layer of food. The food is deposited onto a supportstrip. The supported strip of food is then wound, using a rotating forkwith tines. More specifically, a deformable or pliable food substance isinserted into a containment bin. Rollers which rotate in oppositedirections are positioned below the bin. One roller has a flat facewhereas the other roller, i.e., a forming roller, includes an annulardepression or groove. As the food substance is dropped from the binbetween the rotating rollers, a strip of food is formed at the oppositeof the rotating rollers in the shape of the forming groove. Thegroove-shaped strip of food is deposited or rolled onto a support stripwhich is supplied by a different roller positioned below the formingrollers.

The supported food strip is then cut two times into strips—cut to alength and cut to a width. The strips are passed between legs or tinesof a fork that is driven or rotated by a motor. As a result, a productis formed having a flattened shape. A label is then attached to therolled product to ensure that it does not unroll. The motor and forkassembly are then reciprocated together such that the product rolledaround the fork slides from the fork.

These examples of previously known systems, however, have a number ofshortcomings. First, these systems typically utilize a large number ofcomponents to form a supported strip of food. For example, theconventional roller forming system uses a collection bin, multipleformation rollers, a support material roller, and two cutting systems toform supported strips of food having a certain length and width.Utilizing such a large number of components increases the cost of thesystem and related maintenance, repair and cleaning.

Second, conventional systems typically produce a food item havinglimited selection of ingredients as a result of using a collection bin.If mixtures of food are added to the bin, the output of the bin is noteasily controlled and may contain undesirable mixtures and appearances.

Third, it is inconvenient and aesthetically displeasing when a customermust remove an adhesive label from the rolled food item. Further, thecost of labels and applying the labels can be costly.

Fourth, using a fork for winding the food item is undesirable becausethe length of supported strip of food that is inserted between the forktines must be carefully controlled. Inserting the strip too far betweenthe tines will result in the end of the food strip extending beyond thefork tines. As a result, there can be uneven rolling of the item aroundthe fork. Further, as a result of using a fork, friction forces betweenthe food item and the tines of the fork are greatest at the tines. Thus,when the fork and motor assembly is retracted, food is likely to stickto the tines.

Fifth, known systems that use a fork typically wind the supported foodproduct around the fork without any tension being applied to the productas it is rolled. Consequently, the freely supported roll may not betightly wound, and the rolled product can unwind due to low rolltension.

As a final example, known systems typically lack the ability to adapt toother operating parameters or design configurations. This is due, inpart, to fixed mechanical components. Consequently, if the type of food,support material, operating speeds, size of the food item, etc. must bechanged, these changes may require significant modifications to themechanical design and components of the systems due to the inflexibleparameters.

These shortcomings are further amplified when multiple individual unitsare integrated into a larger scale system. A need, therefore, exists foran apparatus, system, and method that manufactures rolled food items ina more efficient and effective manner than conventional systems. Theimproved apparatus, system, and method should form strips of food itemswithout forming rollers, dual cutting systems, and simplify maintenanceand cleaning, while providing controlled flexibility in selecting fooditems to be wound and design and operating parameters. Indeed, fewermoving mechanical components leads to more efficient and reliableoperation. A need also exists for a food winding apparatus, system andmethod that produces a food item in a more controlled and uniform mannerwith a slotted spool rather than a fork or a self-winding system.Further, a need exists for a large-scale system incorporating theapparatus and method that is capable of manufacturing multiple rolledfood items simultaneously while maintaining flexibility, simplicity, anduser control.

SUMMARY OF THE INVENTION

The present invention provides an improved food winding apparatus,system, and method of forming a rolled food item utilizing a slottedspool or cup and a push plate to eject the rolled food item from thespool without the need for unnecessary cutting systems, forming rollers,or other winding components.

According to the present invention, a food winding apparatus includes amotor, an ejection actuator, a slotted spool, a guide, a push plate, asensor, and a control circuit arranged such that the leading end of alength of a supported strip of food is directed from a roll-up conveyorover the guide. The leading end is detected by the sensor which triggersthe control circuit to activate the motor and rotate the slotted spoolcoupled to the motor shaft after the leading end enters the slot. As aresult, a rolled food item is formed around the spool. After rotatingfor a predetermined number of degrees or after a predetermined number ofspool revolutions, the control circuit activates the ejection actuator,which displaces a member and the push plate attached thereto. As aresult, the plate ejects the rolled food item from the spool.

In further accordance with the present invention, the slot of the spoolmay include a pointed lip to engage the supported strip of food. Theslotted spool may include a pointed lip to engage the supported strip offood and an inner bore or diameter to prevent the supported strip offood from folding upon itself inside the slot. An extruder may depositfood onto the support strip, obviating the need for multiple cuttingsystems and forming rollers.

In further accordance with the present invention, the guide between anend of the roll-up conveyor and the slot of the spool may be springloaded to ensure that the guide is properly aligned with the slot foraccurate insertion of the leading end into the slot. The guide deflectswhen the rolled food item is formed. It is also desirable that the pushplate includes upper and lower portions to distribute pushing forcesaround the rolled food item to more effectively eject the rolled fooditem from the slotted spool.

The rolled food item may be a supported strip of dehydrated fruitproduct. The strip can be maintained in a roll using a drop ofcornstarch or other edible adhesive.

Also in accordance with the present invention, the system can include aplurality of winding units, an extruder, a conveyor system, and a rotaryknife to provide for the simultaneous manufacture of multiple rolledfood items.

Further in accordance with the present invention, a method of formingthe rolled food item can include transporting the supported strip offood on the roll-up conveyor, directing the leading end of the supportedfood strip into the slotted spool, activating the motor to rotate theslotted spool to form the rolled food item, and activating the ejectionactuator to displace the push plate and eject the rolled food item fromthe slotted spool.

This method can include depositing the food item onto the support strip,cutting the supported strip of food to a predetermined length,transporting the supported strip of food on the roll-up conveyor,directing the leading end of the supported food strip into a slottedspool, activating the motor to rotate the slotted spool to form therolled food item, and activating the ejection actuator to displace thepush plate and eject the rolled food item from the slotted spool.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings in which like reference numbers representcorresponding parts throughout:

FIGS. 1A-C are respective top, side, and front views of one embodimentof a food winding unit or apparatus;

FIGS. 2A-C are respective top, side, and front views of the slottedspool of the food winding unit;

FIGS. 3A-B are front views of alternative embodiments of a slotted spoolincluding a pointed upper lip and a bored inner section or diameter;

FIGS. 4A-C illustrate a guide that bridges a gap between an end of asupply or roll-up conveyor and the slotted spool, and the manner inwhich a guide interfaces with the slotted spool;

FIGS. 5A-C are respective front, side, and top views of a spring loadedguide and related spring shaft components;

FIG. 6 is a front view of an assembly of a slotted spool, spring loadedguide, and related spring shaft components;

FIG. 7 illustrates one configuration of a push plate used to eject arolled food item from the slotted spool;

FIG. 8 illustrates the rolled food item being ejected from the slottedspool by an ejection actuator displacing a spool member and push plate;

FIG. 9 illustrates a photoelectric sensor and associated spool and platecomponents;

FIGS. 10A-D illustrate the manner in which a rolled food item is formed;

FIGS. 11A-B are respective top and side views of a system including aplurality of winding units and other system components associated withforming rolled food items;

FIGS. 12A-B are respective top and side views of an alternative systemconfigured with roll-up units arranged on one side of a roll-upconveyor;

FIG. 13 is a front view of a rolling unit mounted on a displaceable baseslide to slide a rolling unit away from its associated conveyor lane;

FIG. 14 is a flow diagram describing the method of forming a rolled fooditem; and

FIG. 15 is a flow diagram describing the method of rolling a supportedstrip of food around a slotted spool.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

In the following description, reference is made to the accompanyingdrawings which form a part hereof, and which is shown by way ofillustration specific embodiments in which the invention may bepracticed. It is to be understood that other embodiments may be utilizedas structural changes may be made without departing from the scope ofthe present invention.

One embodiment provides a food winding unit that winds a supported stripof food into a rolled food item in a uniform and efficient manner usinga slotted spool. A food item is deposited directly onto a strip ofsupport material using, for example, an extruder. While other foodprocessing devices can be used to deposit food onto the support strip,this specification refers to an extruder for purposes of explanation.The food is then cooled to an appropriate temperature to form a solid orsemi-solid food substance. The strips are cut to a predetermined length,having a leading end and a trailing end. The lengths of supported foodstrips are aligned, spaced and directed over a guide, e.g., a guideplate or other guide surface. The presence of the leading end isdetected by a sensor which generates a presence signal indicating thatthe leading end has arrived. The presence signal is provided to amicro-controller which actuates a motor after a predetermined delay.During the delay, the leading end passes over the guide plate and into aslot of a spool.

The spool is coupled to a shaft of the motor. After the predetermineddelay, the motor is activated, thereby rotating the spool, resulting inthe supported strip of food being wound around the spool. After apredetermined number of revolutions, the rolled food item is formed, andthe micro-controller activates an ejection actuator, such as a pneumaticcylinder, to stroke, causing a push plate attached to the cylinder toeject the rolled food item from the slotted spool to a dischargeconveyor below.

These and other aspects of food winding apparatus, system, and methodare described in further detail in the following sections. First, thecomponents of an individual winding unit are described. Then, a systemutilizing 24 individual winding units is described. Finally, a methodfor fabricating a rolled food item with the winding unit and/or systemis described.

Food Winding Unit

As best shown in FIGS. 1A-C, a winding unit 100 includes a motor 110, anejection actuator 120, a slotted roll-up cup or spool 130, a springloaded guide 140 and associated spring shaft components, and a pushplate 150. In addition, the winding unit includes electrical components,such as a sensor 160 (not illustrated), a micro-controller, programmablelogic controller (PLC), or other control unit 170 (not illustrated), andother associated electrical components. First, the mechanical orelectro-mechanical components of the winding unit will be described,followed by the electrical components.

Motor

The motor 110 is mounted to a body or base 112 of the winding unit 100via a bracket such as a slide mount 114 or other attachment. The motor110 is advantageously positioned near the center of the unit body orother location to permit effective placement of other components,although other configurations can be used. When activated, the motor 110drives a shaft 116.

Those skilled in the art will recognize that many types of motors 110can be utilized, one example being a servo motor, part no. 2302-1-F00AA,available from Rockwell Automation/Allen-Bradley Company, 1201 SouthSecond Street, Milwaukee, Wis.

Ejection Actuator

An ejection actuator 120 is also mounted to the base 112 of the windingunit. One example of such an ejection actuator is a pneumatic actuator.For example, FIG. 1B illustrates the ejection actuator 120 mounted tothe slide mount 114, similar to the motor 110. As illustrated in FIGS.1B and 1C, one exemplary pneumatic actuator includes two displaceablemembers or cylinders 122. The pneumatic actuator strokes or displacesthe cylinders 122 from a home position to a distance D.

Various pneumatic actuators can be utilized as part of the winding unit,one example being part no. TB-12-40, available from Bimba ManufacturingCo., Monee, Ill., which drives cylinders 122 to a stroke distance D ofabout 40 mm or 1.57″. Indeed, ejection actuators that stroke todifferent distances can be utilized depending on the design of othercomponents.

Slotted Spool

A slotted spool 130 is coupled to the shaft 116 of the motor 110. Morespecifically, the motor shaft 116 is inserted into a coupling cavity 132within the spool 130. The spool is coupled to the shaft by fastenerssecured through tap holes or bores 133 in the side of the spool body. Asa result, when the motor is activated, the shaft rotates and which, inturn, rotates the slotted spool.

With reference to FIG. 1C, when the spool rotates in a counterclockwisedirection, an upper lip or surface of the slot engages the supportedfood strip inserted therein. The strip of food is then wound around theexterior body of the spool forming the rolled food item.

FIGS. 2A-C illustrate the slotted spool or cup 130 in further detail.Preferably, the spool has a cylindrical outer surface. In oneembodiment, as illustrated in FIG. 2C, the slot 134 of the spool 130 isa rectangular notch extending from one end of the spool through aportion of the spool body. The width of the slot must accommodate thewidth of the supported strip of food.

In an alternative embodiment, as illustrated in FIG. 3A, the slottedspool includes a slot and an upper lip or section formed as a sharpenedor pointed lip 300. The pointed lip 300 can be used to grasp or engagethe supported food strip in a secure manner.

In an alternative embodiment, as best illustrated in FIG. 3B, the spoolincludes a slot with a sharpened or pointed upper lip 300, as well as abored inner section or diameter 302. The slot 134 leads to the boredsection 302, which is generally circular to reduce the supported foodstrip being directed against a back wall of a slot 134 and bent orcrumpled against the back wall. Crumpling may result in the removal ofthe rolled food item from the spool 130 being made more difficult if thefood sticks to the slot surfaces. However, with an inner bore ordiameter 302, the supported strip of food can glide along the bottomsurface and in an upward direction along the inner diameter, andpossibly folding upon itself. As a result, the lower friction supportmaterial glides along the inner slot surface and less food contactsinner surfaces of the bore/slot. This design reduces the amount of foodthat sticks to the slot, thereby making removal of the food item fromthe spool easier.

Furthermore, the spool surfaces which contact the supported food stripcan be coated with a low friction substance, e.g., TEFLON®, to furtherreduce friction. As a result, the food does not stick to spool surfaceswhen the rolled product is ejected from the spool.

The slotted spool designs described above are advantageous compared toother conventional systems, since the supported strip of food is woundin a uniform manner around the spool instead of in an uneven orflattened manner. Further, when the strip enters the slot, it iscontained within the body of the slot and/or inner diameter of thespool. This controlled winding is in contrast to systems which use afork. With a fork, the leading end can extend past the fork tines,thereby resulting in uneven winding or other winding irregularities as aresult of the supported strip of food extending beyond the fork tines.This potential problem is obviated with a slotted spool.

The slotted spool also includes a groove 135 around a portion of thecylindrical surface. The groove 135 receives a flange of the guide 140to align the guide with the slot 134, and direct the supported foodstrip into the slot 134, as described in further detail below.

Guide

As shown in FIGS. 1A-C, a spring loaded guide 140, e.g., a guide plateor other guide surface, is positioned between an end of the roll-up orsupply conveyor (not shown) that transports the supported food strip tothe slotted spool 130. In other words, the guide bridges the gap betweenthe end of the conveyor and the slot of the spool and ensures that theleading end of the food strip is properly inserted into the slot.Further, as the rolled product is formed, the guide is deflected by theproduct, thereby providing tension to the roll as it is formed. As aresult, a tighter rolled food product can be formed, and the rolledproduct is less susceptible to unrolling or unraveling. Thus, packagingbecomes more efficient since unraveled portions do not have to beadjusted.

An exemplary guide in the form of a guide plate is illustrated infurther detail in FIGS. 4A-C. The guide 140 is generally rectangular andincludes a tongue or flange 400, a sensor aperture 410, and connectionholes 420. FIGS. 4B-C illustrate the guide 140 interfacing with theslotted spool 130. More specifically, the flange 400 is aligned with andis received by the corresponding groove 135 of the slotted spool 130. Asshown in FIG. 4B, the flange 400 is inserted within the groove 135 (FIG.4C illustrates a side view of the same).

The guide 140 is spring loaded through an associated shaft and springassembly, as illustrated in FIGS. 5A-C. The guide 140 is secured to aspring shaft 500 through mounting holes 420 with appropriate fasteners.The spring shaft 500 is mounted in a housing 510.

The spring shaft 500 can have a cylindrical section 502 and asemi-circular or flattened section 504 for attachment to a face of theguide 140. Of course, other attachment designs can be utilized.

Referring to FIGS. 5A-B, the spring shaft 500 passes through a springshaft housing 510. The spring shaft housing 510 is secured to a springhousing plate or base 520. A spring 530 is coupled between mountingclasps. A mounting clasp 540 is coupled to an end of the spring shaft500 which is opposite the guide plate via, e.g., a screw 541 or otherfastener. Similarly, a mounting clasp 542 is coupled to a side of thespring shaft housing 510 via, e.g., a screw 543 or other fastener.

With this arrangement, the guide 140 is held in tension by spring 530.One example spring 530 that can be utilized is a spring having thefollowing attributes: uninstalled length of about 1.5 inches having atension of about 2.5 lbs/inch; installed length of about 2 inches havinga tension of about 3.0 lbs/inch; maximum length of about 2.5″ having atension of about 5.0 lbs/inch; and a maximum spring tension of about10.0 lbs/inch. Indeed, other spring lengths and tensions can be useddepending on the configuration and parameters of other systemcomponents. Thus, the recited lengths and tensions are merely examplesfor purposes of explanation.

The tension of the spring 530 enables the guide plate 140 to bedeflected by a relatively small force, e.g., by the force of a rotatingrolled food item. As the rolled food item is formed, the guide 140deflects a greater distance, extending the spring 530 and partiallyrotating the spring shaft 500 in the same direction. For example, FIG.5A illustrates the spring shaft 500 and mounting clasp 540 in twodifferent positions—a rest position and a deflected position (mountingclasp in an elevated position) as a result of the guide 140 beingdeflected by a rolled food item (deflected guide not shown).

FIG. 6 is a side view of an assembled spring loaded guide 140 andslotted spool 130. The guide is positioned between the end of theconveyor (not shown) and the slotted spool such that the flange 400 ofthe guide is aligned with a receiving groove 135 around the cylindricalperimeter of the slotted spool 130. In this configuration, the spool canrotate (e.g., counterclockwise) to form the rolled product, and duringthe rolling process, the guide deflects downward as the rolled item isformed. However, the guide does not impede the spool=s rotation or theformation of the rolled product. Instead, the tension in the spring 530is selected such that the spool 130 can rotate with the flange 400within the receiving groove 135 with or without a rolled food itemformed thereon.

Ejection Plate

As shown in FIGS. 1A-C, after the rolled food item is formed on thespool, the ejection actuator 120, such as a pneumatic cylinder actuator,is activated. As a result, cylinders 122 and an attached ejection orpush plate 150 are displaced to a stroke distance D. This distance isselected to be sufficient to push or eject and disengage the rolled fooditem from the slotted spool, e.g., D≧length of spool, or D≧the width ofthe support strip.

FIG. 7 illustrates the push plate 120 in further detail. The push plateincludes two mounting holes 700 for connection to the two shafts orcylinders 122 of the ejection actuator. The plate is designed to ejectthe rolled food item from the slotted spool. It can be designed in manydifferent ways, one of which is illustrated in FIG. 7. For example, thebottom portion of the push plate includes a partially open aperture 702with a diameter sufficiently wide to accept the slotted spool. As aresult, the slotted spool can freely rotate without interference fromthe plate.

The bottom portion of the ejection plate also includes a lower lip 704which extends around a portion of the bottom of the aperture 702. As aresult, the upper portion 701 and lower lip 704 provide pressure to thetop and bottom portions of the rolled food item to provide moredistributed or equalized pressure against the side or body of the rolledfood item.

Continuing with reference to FIG. 8, when the winding unit is at rest orin the process of forming a rolled food item, the push plate 150 isnormally in a home position 800, i.e., positioned against the side wallor surface of the winding unit housing. In this state, the ejectionactuator 120 has not displaced its cylinders 122. As a result, the pushplate 150 does not interfere with the rotation of the slotted spool 130or the deflection of the guide 140 since the push plate 150 ispositioned to the side of these components. Further, aperture 202permits the spool to rotate therein.

However, after a predetermined number of revolutions or degrees ofrotation of the motor shaft 126 and/or slotted spool 130, the ejectionactuator 120 is activated by the micro-controller 170. For example, theejection actuator can be activated after about 2 to about 20revolutions, one example being about 5 revolutions, depending on thediameter of the spool. The ejection actuator displaces its cylinders 122and push plate 150 connected thereto to the stroke distance D, i.e., anejection position 804. As a result, the push plate 150 ejects the rolledfood item 810 from the spool 130 to a discharge conveyor positionedbelow.

After ejecting the rolled product 810 from the spool 130, the ejectionactuator 120 and push plate 150 return to the home position 800, and theprocess repeats for additional rolled food items as necessary.

Having described the mechanical/electro-mechanical components of thewinding unit 100 and their general operation, there follows a moredetailed description of the electrical components that control thesemechanical/electro-mechanical components. These electrical componentsinclude the sensor 160 for detecting the leading end of a supported foodstrip and the micro-controller 170 for controlling the operation of themotor 110, ejection actuator 120, and other components and operatingparameters.

Sensor

Referring to FIGS. 9 and 10A-D, the edge detection sensor or photoeye160 is positioned above the aperture 410 of the guide 140. The sensor160 produces a beam 900 and detects the leading end of a supported foodstrip. Many different sensors can be used for this purpose, one examplebeing a photoelectric infrared sensor, part no. 42BA-S2LPAC-A2, which isalso available from Allen-Bradley.

Referring back to FIG. 1A or 4A, the guide plate includes a sensoraperture 410 to permit the beam 900 to pass through the guide 140. Whenthe leading end of a supported food strip passes over aperture 410, itbreaks the beam 900 from the sensor 160. As a result, the sensor 160detects the leading end, and generates a presence signal in responsethereto. The presence signal indicates to the micro-controller 170 thatthe leading end has passed a predetermined point or location, e.g.,aperture 410 of guide 140.

Micro-Controller

The micro-controller 170 controls the operating parameters of thewinding unit 100 components and can be programmed to control differentoperating parameters and settings.

For example, when sensor 160 generates the presence signal indicatingthe detection of the leading end, the micro-controller 170 is triggeredto activate the motor 100 after a delay period to permit the leading endto continue over the guide plate 140 and into the slot 134 of the spool130. An exemplary time delay is 100 ms if the supported food strip isbeing transported by a supply conveyor at about 1 foot per minute (fpm)to about 40 fpm, one example being about 35 fpm. After the time delay,i.e., after the leading end has entered the slot 134, themicro-controller activates the motor, thereby rotating the shaft andslotted spool to form the rolled food item. Further, persons of ordinaryskill in the art will recognize that one or more micro-controllers cancontrol one or more roll-up units. For example, although thisspecification refers to one micro-controller 170, alternatively, onemicro-controller can control one group of roll-up units (e.g., 12units), and a second micro-controller 170 can control a second group ofroll-up units (e.g., 12 units).

FIGS. 10A-D illustrate the manner in which the sensor 160 andmicro-controller 170 are utilized to control the rotation of the motor110 and spool 130 to form a rolled food item.

First, with reference to FIG. 10A, the winding unit is in its homeposition. The roll-up or supply conveyor 1000 is either inactive or inthe process of transporting a supported food strip before the sensor160. In addition, the motor 110, ejection actuator 120, and the slottedspool 130 are at their home positions. Further, the spring loaded guide140 is not deflected since there is no rolled food item to deflect theguide 140.

Thus, FIG. 10A illustrates the leading end 1011 of the supported foodstrip 1010 being transported by the supply conveyor 1000, but not so farenough to break the sensor beam 900. As a result, the signal from thesensor 160 indicates that the leading end 1012 has not been detected. Anedge detection light emitting diode (LED) 1020 can be illuminated in anamber color to indicate that the leading end has not been detected. Inaddition, a LED 1022 can indicate power to the winding unit.

Next, with reference to FIG. 10B, the leading end 1012 is transported bythe roll-up conveyor 1000, onto the guide plate 140. The leading endbreaks the beam 900 of the sensor. In response, the sensor 160 generatesthe presence signal and provides this signal to the micro-controller170. Detecting the leading end 1012 can also be indicated by a greenedge detection LED 1020.

However, in this exemplary design, the motor 110 does not immediatelybegin rotating upon detection of the leading end 1012. Rather, thepresence signal indicates to the micro-controller 170 that the motor isactivated after a delay period 1030 (e.g., 100 ms) to permit the leadingend to enter the slot. Thus, FIG. 10B illustrates the motor 110,ejection actuator 120, spool 130, guide 140, and push plate 150 in theirhome positions, since the leading end 1012 has just been detected.

Next, with reference to FIG. 10C, the conveyor 1000 continues totransport the food strip 1010 across the guide plate 140. The leadingend 1012 enters the slot 134. After the delay period 1030 has expiredand the leading end 1012 enters the slot 134, the motor 110 is activatedto rotate the slotted spool 130 with the leading end 1012 therein. Anindex cycle begins in which the motor 110 and/or spool 130 rotate for apredetermined number of revolutions.

Finally, with reference to FIG. 10D, the motor 110 and slotted spool 130have rotated their respective predetermined number of revolutions toform a rolled food item 810. As a result, the guide 140 is deflecteddownward as the rolled food item 810 is formed. After the predeterminednumber of revolutions, a control circuit of the motor issues a signal tothe micro-controller that the index cycle has completed. Themicro-controller 170 activates the ejection actuator 120 to displace thepush plate 150 from its home position to the stroke distance D. Therolled food item 810 is then ejected from the spool 130 and falls to adischarge conveyor located below (not illustrated).

Besides controlling the motor and ejection actuator, themicro-controller 170 can also control other aspects of the winding unit.For example, the micro-controller can be programmed with different delayperiods 1030 depending on the speed of the roll-up conveyor 1000.Further, the micro-controller 170 can be programmed to activate themotor 110 for different numbers of revolutions to form a rolled fooditem with different numbers of layers. The number of revolutions canalso be adjusted depending on the thickness of the support material andfood item. Additionally, the micro-controller 170 can control when theejection actuator 120 is initiated to displace the cylinders 122 astroke distance D to eject the rolled food item from the spool with thepush plate.

These and other control aspects are further explained with reference toa system including one or more of the previously described windingunits.

Food Winding System

One or more winding units 100 can be incorporated into a system forproducing a rolled food item. One example system is illustrated in FIGS.11A-B. FIG. 11A illustrates a top view of one embodiment of the windingsystem 1100, and FIG. 11B illustrates a side view of the same system.

With reference to FIG. 11A, the system 1100 includes 24 food windingunits 100. Indeed, those skilled in the art will recognize that manydifferent numbers of food winding units 100 can be utilized, and asystem with 24 units 100 is illustrative of many configurations that canbe used.

In this embodiment, the winding system 1100 includes: 24 supply reels1102 with support material or strips 1104, an extruder 1110 with headsor ports 1112 through which food is deposited on support strips 1104positioned below respective heads 1112, a cooling conveyor system 1120,a cooling tunnel 1122 (if necessary), a vacuum system 1130, a gluesystem 1140, a cutting system 1150, a spacing conveyor system 1160 (ifnecessary), a roll-up conveyor system 1170, winding units 100 at the endof the roll-up conveyor system 1170, and a discharge conveyor system1180 to transport rolled food items ejected from the winding units 100.

Supply Reels

Twenty-four support strips 1104 from 24 supply reels 1102 (or sparereels) are directed under the extruder 1110. In the event that a supplyreel 1102 is almost empty, a sensor which monitors the support materialremaining on a primary or spare supply reel can alert a user that newsupply reels are needed.

Extruder

Extruders which deposit food items are well known. Various types ofextruders 1110 can be used with the food winding system 1100, oneexample being a side flow extruder. The extruder deposits a food item1111 through 24 extruder heads or ports 1112 onto respective supportstrips 1104 which pass below each head 1112 along the cooling conveyorsystem 1120. For example, a support strip can have a thickness of about0.010″ to 0.1″, one example thickness being 0.020″. The support stripcan have a width of about 0.35″ to about 24.2″, one example width being1.125″. The food can be dispensed by the extruder at a temperature ofabout 100° F. to about 240° F., one example temperature being 200° F.The thickness of the food can be about 0.25″ to about 24″, one examplefood thickness being about 0.062″. The width of the food can be about0.25″ to about 24.0″, one example being about 0.75″ (narrower than thewidth of the support strip).

The extruder 1110 provides flexibility in the manner in which food isdeposited onto the support strip 1104. For example, the extruder 1110can be set to deposit food 1111 in a continuous manner onto continuoussupport strips 1104 as previously described. Alternatively, the supportmaterial 1104 can be perforated such that strips of support material arereleased from supply reels 1102 into strips of a predetermined length.The lengths may or may not include spaces therebetween. If there are nospaces between the pre-cut lengths of support strips, the extruder 1110can continuously deposit food onto the strips. If, however, the supplyreels 1102 are configured to release spaced strips onto the conveyor,then the extruder 1110 can be controlled to periodically deposit food1111 onto the spaced support strips 1104 in order to maintain the timingof depositing food onto a support strip. Thus, the extruder 1110 can becontrolled to periodically or continuously deposit food 1111 ontosupport strips 1104 depending on the design and required timing.

Moreover, the extruder 1110 provides flexibility in the type of food1111 that is wound into a rolled food item. For example, one extruder1110 can provide a food item 1111 to ports 1-12, whereas anotherextruder 1110 with another food item 1111 can provide its food item toports 13-24. An extruder can also be partitioned such that differentheads deposit different types of food. Thus, the system is flexible andcan produce different rolled food items. Further, the extruder 1110 canbe used to controllably mix ingredients and colors, further enhancingthe capability of the winding system.

Cooling Conveyors and Tunnel

The supported food strips are transported by the cooling conveyors 1120,and the food item cools while moving along the cooled conveyor surfaces,e.g., at 1 foot per minute (fpm) to about 40 fpm, one example beingabout 35 fpm. The cooling conveyors can be cooled using, for example,cooling plates at a temperature of about 55 to 65 degrees F. The totallength of the cooling conveyors from the extruder to the rotary knifecan be about 100 feet. The food 1111 is cooled to a temperature of about60° F. to about 120° F., one example being about 70° F. Of course,different cooling temperatures and cooling durations can be selecteddepending on the speed of the cooling conveyor 1120, the type of fooditem(s) 1111, and the desired cooling effect. Further, if necessary, acooling tunnel 1122 can be utilized for enhanced cooling effects.

Vacuum Alignment

Upon exiting the cooling tunnel 1122, the supported food strips aretransported by the cooling conveyor 1120 to a vacuum system 1130. Anexemplary vacuum system includes a vacuum pump 1132 (e.g., a 2.0horsepower vacuum pump) and vacuum plenum or ports 1134 below thecooling conveyor 1120. The pump 1132 creates a vacuum through the ports1134. Thus, when the supported strips of food enter the vacuum section,they are aligned in lanes as a result of the suction generated by thepump through ports 1134 upon the bottom of the support material.

Glue System

An adhesive or glue is applied to the trailing end of the length ofsupported food strip using a glue system 1140. In a preferredembodiment, the adhesive is edible, e.g., a drop of an edible food gradeadhesive such as cornstarch, is applied to the trailing end of eachstrip through nozzles 1142 and secures the food strip to the back of thesupport strip when a rolled food item is formed. Other edible adhesives,such as moisture or water, can also be utilized depending on the foodstrip composition and support strip material. This technique isadvantageous because it is not necessary to remove labels or othernon-edible adhesives from the rolled product. Of course, a label andother different adhesives can also be utilized, or the food may besufficiently cohesive that this is unnecessary.

Cutting System

To this point, the supported food strips have been chilled, aligned, andreceived an adhesive. Assuming the extruder deposits a continuous stripof food onto a continuous support strip, the supported food strip isalso continuous. The strip is then cut by the cutting system 1150.

The exemplary cutting system 1150 includes a rotary knife 1152 driven bya knife motor 1154. The rotary knife 1152 includes a single blade whichrotates about a shaft and extends across the cooling conveyor 1120,i.e., across the width of the strips of supported food. Thus, as each ofthe 24 continuous strips of food pass under the rotary knife 1152, eachstrip is cut to a predetermined length.

Of course, those skilled in the art will recognize that other knifeconfigurations can be utilized. For example, instead of a single blade,multiple blades can be used to cut a supported strip of food intopredetermined lengths. Further, the rotation speed of the knife 1152,the speed of the cooling conveyor 1120, or a combination of the rotationspeed of the knife and speed of the cooling conveyor can be adjusted tocut the supported food strip into different lengths. Moreover, a slicingmechanism can be utilized instead of a rotary knife. With thisconfiguration, a blade can traverse the width of the conveyor, cuttingeach strip to a predetermined length. In the slicing configuration, theconveyor can be momentarily paused to complete the slicing action.

In an alternative embodiment in which the supply reel 1102 is perforatedto provide predetermined lengths of support material under the extruder,the rotary knife is not needed since the strips are already cut orperforated to a predetermined length. In fact, no cutting mechanism isnecessary in this embodiment since the support strips from such supplyreels are also pre-cut to a predetermined width.

The predetermined length is preferably consistent for each of the 24winding units 100 to simplify the configuration and control of the othercomponents. For example, a continuous supported strip of food can be cutby the rotary knife 1152 into lengths of about 6″ to 72″, one examplebeing 36″.

Once the predetermined length is selected, the parameters of othercomponents can be set, e.g., the number of rotations of themotor/slotted spool to wind the food strip.

Spacing Conveyors

One embodiment of the system utilizes a spacing conveyor that runsfaster than the vacuum conveyor to create gaps between strips of fooditems after they are cut into predetermined lengths. The spacingconveyors 1160 which are driven by a spacing conveyor motor 1162. Thelength of the spacing conveyors is about 4 feet. The spacing conveyor1160 runs at a higher speed than the cooling conveyor 1120. As a result,when lengths of supported strips of food are transferred to the spacingconveyors 1160, the leading length proceeds at a faster rate compared toa trailing length. Consequently, a space develops between the leadingand trailing lengths of supported food strips in the same lane or on thesame conveyor.

Thus, larger spaces between lengths of supported food strips can beformed by increasing the speed differential between the spacing conveyor1160 and cooling conveyor 1120. For example, the spacing conveyor cantransport the predetermined lengths of supported food strips about 15%faster than the cooling conveyor.

Persons of ordinary skill in the art will recognize that spaces betweencut strips of food item can be generated in other ways. For example, inan alternative embodiment, the system does not utilize a spacingconveyor. Instead, the speed of the rolling process can be increased sothat a sufficient gap between the strips of food is created to allowsufficient time for the roll-up unit to reset for the next roll-upsequence.

Roll-up/Supply Conveyors

The lengths of supported food strips are directed to winding or roll-upconveyors 1170 which are driven by a winding conveyor motor 1172, andthen to respective winding units 100. The roll-up conveyors can betransported at a speed of about 1 foot per minute (fpm) to about 40 fpm,one example being about 35 fpm, similar to the cooling conveyor.

In the embodiment illustrated in FIG. 11A, a top view of the system,winding units 100 are arranged in a triangular or V-shapedconfiguration. More specifically, this arrangement includes 24 windingunits offset by, for example, 12 inches. Of course, different offsetscan be utilized. The lengths of the roll-up conveyors can vary due tothe offset positions, and can range from about 40″ to about 162″ inlength with 12″ offsets between each winding unit. The spacing of thewinding units 100 enables the supported strips of food to be woundwithout interference from other winding units.

The exemplary triangular or V-shaped configuration of the system isillustrated in FIG. 11B. The winding units 100 are also arranged atdifferent elevations. For example, adjacent conveyors can have about a2″ height differential. Again, this reduces or prevents interferencebetween winding units. The variations in the lengths of the roll-upconveyors are due, in part, to the vertical rise and horizontal lengthof individual conveyors at the downstream end and to provide sufficientspace for the push plate and ejection of the rolled product from thespool.

Discharge Conveyors

As discussed earlier, each winding unit forms a rolled food item withthe slotted, rotating spool or cup. Then, the rolled food item isejected from the spool by the push plate displaced by the ejectionactuator. The rolled food item then falls onto a discharge conveyor 1180which is driven by a discharge conveyor motor 1182. The rolled fooditems can then be routed to other processing or packaging systems.

Persons of ordinary skill in the art will recognize that other systemconfigurations besides the “elevated V” configuration shown in FIGS.11A-B can be used. For example, referring to FIGS. 12A-B, in analternative embodiment of a winding system, the winding units 100 can bearranged on one side of the roll-up conveyor 1170 instead of arrangedacross the roll-up conveyor in a “V” design. In this alternativeembodiment, the discharge conveyor 1180 is positioned below the windingunits 100 so that the rolled food item can be ejected from the spool bythe push plate and fall onto the discharge conveyor 1180 below. Thus, 24conveyor lanes can be used to produce 24 rolled food products in anarrower area, e.g., in approximately a width of 35″, whereas oneembodiment of the “V” embodiment shown in FIGS. 11A-B uses a width ofabout, e.g., 45″ to 65″. Additionally, in it is not necessary to elevatethe roll-up units.

Also in connection with the alternative embodiment previously described,referring to FIG. 13, the base of one or more of the winding units 100can be attached to a slide base 1300. The slide base 1300 is displacedby a cylinder (not shown in FIG. 13) of a slide actuator 1310 (e.g., aBimba Manufacturing Co. actuator as previously described). The slidebase 1300 under each winding unit 100 can be displaced by the slideactuator 1310 to retract the roll-up unit 100. More specifically, therolled food product is wound around the spool as previously described.The roll-up unit 100 can be displaced away from its associated roll-upconveyor lane when the micro-controller activates the slide actuator1310 so that its cylinder and the base 1300 connected thereto aredisplaced. The slide base 1300 and the winding units are displaced froman initial or winding position to a retracted position at the actuator'sstroke distance. The ejection actuator 120 coupled to the push plate isthen activated to eject the rolled food item from the spool. The slideactuator 1310 and the base slide 1300 then return to their initialpositions. As a result of sliding the winding unit back before therolled food item is ejected, the ejected rolled food item falls in frontof its own conveyor. Thus, the winding and food item ejection processcan be completed within a narrower area.

Having described the general operation of a food winding unit 100 and asystems 1100 and 1200 utilizing multiple winding units 100, thefollowing sections provide further details about the method of forming arolled food item.

METHOD OF FORMING ROLLED FOOD ITEMS

Following is a description of the steps performed for producing aplurality of rolled food items. This method can be utilized to form asingle product or different numbers of products.

Referring to the flow chart of FIG. 14, in step 1400, the type of fooditem to be rolled into food items is selected. That food item, orcombination of food items (e.g., different ingredients, colors,flavorings, etc.) is added to an extruder or other food depositingmachine.

Next, in step 1402, the food item(s) is deposited through one or moreextruder heads onto support strips positioned below the extruder heads.For example, the support strips can be one of many different food gradeflexible support materials including, but not limited to, siliconecoated paper, cellophane, and polyethylene. having a thickness fromabout 0.010″ to about 0.1″, one example thickness being about 0.020″,and a width from about 0.35″ to about 24.2″, one example being about1.125″. The food can be dispensed by the extruder at, for example, atemperature from about 100° F. to about 240° F., one example being about200° F., with a thickness from about 0.04″ to about 0.5″, one examplebeing about 0.062″, and a width of about 0.25″ to about 24″, one examplebeing about 0.75″.

Continuing with step 1404, the supported food strips are transported bythe cooling conveyor at a rate of about 35 feet per minute (fpm). Otherspeeds can be used depending on the settings of other relatedcomponents. In step 1406, the supported food strips are aligned using,for example, a vacuum system.

In step 1408, the supported food strips are transported by the coolingconveyor through a cooling tunnel which cools the food from about 200degrees Fahrenheit to about 70 degrees Fahrenheit. Upon exiting thecooling tunnel, in step 1410, an adhesive is periodically applied to thefood. The adhesive can be cornstarch or another edible adhesive thatattaches the food item to the backing or support material. Of course, alabel can also be utilized.

At this point, the supported food strips have not been cut. Rather, thestrips are continuous and food is deposited upon the strips in acontinuous manner. Thus, the drops of cornstarch can be appliedperiodically, e.g., applied about 1 inch from the cuts—on the trailingends of the eventual lengths of supported food. In the exemplaryembodiment involving 36 supported food strips, the drops of cornstarchor other edible adhesive are applied every 36″ and 1″ from what will bethe trailing ends of the lengths of supported food. Of course, thecornstarch can be applied at different intervals depending on the foodproduct. Then, in step 1412, the supported food strips are cut tolengths with the rotary knife or other cutting mechanism.

Those skilled in the art will recognize that it is not necessary toperform these method steps in the order recited above. For example, thedrops of cornstarch or other edible adhesive can be applied to thetrailing ends of lengths of food after the continuous strips are cut.

Continuing with step 1414, the lengths of supported food strips arespaced using spacing conveyors. Spacing the strips in this mannerprovides time, for the winding units to wind the strips into rolledproducts without interference from other strips. Next, in step 1416, thelengths of supported food strips are wound into rolled food items. Then,in step 1418, the rolled products are ejected from the spools andprovided to discharge conveyors for further processing. (FIG. 15 is aflow chart providing further details relating to step 1416, winding astrip of food into a rolled food item using a winding unit 100.)

In step 1500, the roll-up conveyor transports the supported food stripstowards the slotted spool. In step 1502, the strip is furthertransported such that the leading end is provided to the guide platebetween the end of the roll-up conveyor and the slotted spool. Then, instep 1504, the leading end passes over the sensor aperture of the guideplate, thereby breaking the beam of the sensor. As a result, in step1506, the sensor generates a presence signal indicating that the leadingend has reached a location breaking the beam of the photosensor.

Then, in step 1508, the presence signal is provided to themicro-controller. In step 1510, the micro-controller implements a delaybefore activating the motor to permit the leading end to traverse theguide plate and enter the slot of the spool. In step 1512, after thedelay has expired and the leading end has entered the slot, themicro-controller activates the motor and begins an index cycle, therebyrotating the motor shaft and slotted spool coupled thereto. In step1514, the motor shaft and slotted spool rotate for a predeterminednumber of revolutions to form the rolled food item. Then, in step 1516,the motor control circuit generates a signal indicating an index cyclehas been completed.

In step 1518, the index cycle complete signal is provided to themicro-controller. In step 1520, in response to the index cycle completesignal, the micro-controller activates the actuator. As a result,actuator cylinders and the push plate coupled thereto are displaced to astroke distance D. Then, continuing with step 1518, the rolled food itemis ejected from the slotted spool by the push plate.

Those skilled in the art will recognize that the above methods can beutilized with a single winding unit or with a system including one or aplurality of winding units as previously described. Although referenceshave been made in the foregoing description to various embodiments,persons of ordinary skill in the art of designing food winding units andrelated systems will recognize that insubstantial modifications,alterations, and substitutions can be made to the described embodimentswithout departing from the invention as claimed in the accompanyingclaims. Thus, while the preferred embodiment is described as utilizing aslotted spool and a push plate to eject the rolled food item from theslotted spool, those skilled in the art will recognize that othersimilar mechanisms can also be utilized.

Further, persons of ordinary skill in the art will recognize that manyvariables in the system of winding units can be selected to accommodatedifferent operating parameters, e.g., speeds of cooling, spacing, androll-up conveyors, the cooling temperature of the cooling conveyordepending on the speed of the cooling conveyor, lengths of supportedstrips of food, time delay between detecting the leading end of a stripof food and initiating rotation of the motor and slotted spool, thenumber of rotations to form the rolled food item, the length and widthof the food item, support strips, and resulting rolled food item, thestroke distance D of the pneumatic actuator, speed and number of bladesof the rotary knife, and the design of the push plate, slot (e.g.,pointed lips, bored inner diameters), and guide plate (e.g., tonguedesign to interface with slot of spool and spring tension), and themanner of controlling these components, as different operatingparameters can be controlled through programming a micro-controller toimplement the parameters. Further, various system configurations can beused, including arranging the winding units in an elevated “V”configuration or arranging the winding units on one side of the roll-upconveyor.

1. An apparatus for winding a supported strip of food having a leadingend and a trailing end into a rolled food item, comprising: a motorhaving a shaft which rotates when said motor is activated; a spoolhaving a slot, said spool being coupled to said shaft of said motor,whereby said slotted spool rotates when said motor is activated; a guidepositioned before said slot to direct the leading end of the supportedfood strip into said slot; a sensor positioned above said guide todetect the leading end and to generate a presence signal in responsethereto; an actuator with a displaceable member; a plate coupled to saiddisplaceable member, said plate being positioned to permit said spool torotate to form the rolled food item; and a control circuit associatedwith said motor, sensor, and actuator, said control circuit configuredto activate said motor in response to said presence signal and to rotatesaid slotted spool a predetermined number of degrees to form the rolledfood item and, after said predetermined number of degrees, and toactivate said actuator to displace said plate and eject the rolled fooditem from said slotted spool.
 2. The apparatus of claim 1, wherein saidmotor is activated to rotate said slotted spool about five revolutionsto form the rolled food item.
 3. The apparatus of claim 1, wherein saidslot is formed through one side of said spool.
 4. The apparatus of claim1, wherein said spool includes a sharpened lip to engage the food. 5.The apparatus of claim 1, wherein said spool includes a sharpened lip toengage the food and an inner diameter to receive the supported foodstrip.
 6. The apparatus of claim 1, wherein said slotted spool has acylindrical outer surface.
 7. The apparatus of claim 1, wherein saidguide includes an aperture, and said sensor is positioned adjacent saidaperture and generates a beam that passes through said aperture, andwherein said sensor detects the leading end by the leading end breakingthe beam.
 8. The apparatus of claim 1, further comprising a springcoupled to said guide, said spring being configured to place said guidein tension to maintain said guide in a position aligned with said slot.9. The apparatus of claim 8, wherein said guide includes a flange, saidslotted spool includes a groove about a perimeter of said spool; andsaid flange is received within said groove to align said guide with saidslot of said spool.
 10. The apparatus of claim 11, wherein said guide isdeflected under tension by said spring as a result of the rolled fooditem being formed around said slotted spool.
 11. The apparatus of claim1, wherein said sensor comprises an infrared sensor.
 12. The apparatusof claim 1, wherein said actuator comprises a pneumatic cylinder. 13.The apparatus of claim 1, wherein said plate includes an upper sectionwhich applies pressure against the top of the rolled food item and alower section which applies pressure against the bottom of the rolledfood item.
 14. The apparatus of claim 1, wherein said control circuitcomprises a micro-controller.
 15. The apparatus of claim 1, wherein saidcontrol circuit activates said motor in response to said presence signalafter a predetermined delay, said predetermined delay permitting theleading end of the supported food strip to enter said slot of saidspool.
 16. The apparatus of claim 15, wherein said predetermined delaycomprises 100 ms when the supported food strip is being transported atabout 35 feet per minute (fpm).
 17. The apparatus of claim 1, whereinthe rolled food item comprises a dehydrated fruit product.
 18. Theapparatus of claim 1, wherein the trailing end of the supported foodstrip is adhered to the rolled food item by a drop of an edibleadhesive.
 19. A system for winding one or more supported strips of foodhaving a leading end and a trailing to form a rolled food item,comprising: an extruder configured to deposit food onto a support strip;a cutter to form predetermined lengths of supported food strips; aconveyor to transport said supported food strip; and a winding unitpositioned at an end of said conveyor and configured to receive theleading end of the supported food strip, said winding unit including: amotor having a shaft which rotates when said motor is activated; a spoolhaving a slot, said spool being coupled to said shaft of said motor,whereby said slotted spool rotates when said motor is activated; a guidepositioned before said slot to direct the leading end of the supportedfood strip into said slot; a sensor positioned above said guide todetect the leading end and to generate a presence signal in responsethereto; an actuator with a displaceable member; a plate coupled to saiddisplaceable member, said plate being positioned to permit said spool torotate to form the rolled food item; and a control circuit associatedwith said motor, sensor, and actuator, said control circuit configuredto activate said motor in response to said presence signal and to rotatesaid slotted spool for a predetermined number of degrees to form therolled food item and, after said predetermined number of degrees, toactivate said actuator to displace said plate and eject the rolled fooditem from said slotted spool.
 20. The system of claim 19, wherein saidextruder deposits a continuous strip of food onto the support strip. 21.The system of claim 20, wherein the support strip has a width of about1.25″ and the deposited food has a thickness of about 0.062″ and a widthof about 0.75″.
 22. The system of claim 19, further comprising a coolingsystem to cool the food deposited by said extruder.
 23. The system ofclaim 22, wherein said cooling system comprises a cooling tunnel throughwhich the supported food strip is transported by said conveyor.
 24. Thesystem of claim 23, wherein the food is cooled in said cooling tunnel toa temperature of about 70 degrees F.
 25. The system of claim 19, whereinsaid cutter comprises a rotary knife including a shaft extending thewidth of the supported food strip and at least one blade, said shaft andblade being rotated to cut said supported food strip to saidpredetermined length.
 26. The system of claim 25, wherein saidpredetermined length comprises about 36″.
 27. The system of claim 19,wherein said conveyor comprises: a cooling conveyor positioned betweensaid extruder and said cutter; a spacing conveyor positioned after saidcooling conveyor, wherein said spacing conveyor is faster than saidcooling conveyor resulting in said spacing conveyor producing spacesbetween predetermined lengths of supported food strips; and a windingconveyor positioned after said spacing conveyor to transportpredetermined lengths of supported food strips.
 28. The system of claim27, wherein said cooling conveyor transports said supported food stripat about 35 feet per minute (fpm).
 29. The system of claim 27, whereinsaid spacing conveyor transports said predetermined lengths of supportedfood strips about 15% faster than said cooling conveyor.
 30. The systemof claim 27, wherein said winding conveyor transports said predeterminedlengths of supported food strips at about 35 feet per minute (fpm). 31.The system of claim 19, wherein said motor rotates said slotted spoolfor about five revolutions to form the rolled food item.
 32. The systemof claim 19, wherein said slot is formed through one side of said spool.33. The system of claim 19, wherein said spool includes a sharpened lipto engage the food.
 34. The system of claim 19, wherein said spoolincludes a sharpened lip to engage the food and an inner diameter toreceive the supported food strip.
 35. The system of claim 19, whereinsaid slotted spool has a cylindrical outer surface.
 36. The system ofclaim 19, wherein said guide includes an aperture, and said sensor ispositioned above said aperture and generates a beam that passes throughsaid aperture, and wherein said sensor detects the leading end by theleading end breaking the beam.
 37. The system of claim 19, furthercomprising a spring coupled to said guide, said spring being configuredto place said guide in tension to maintain said guide in a positionaligned with said slot.
 38. The system of claim 37, wherein said guideincludes a flange; said slotted spool includes a groove around aperimeter of said spool; and said flange is received within said groovefor alignment of said guide plate with said slot of said spool.
 39. Thesystem of claim 19, wherein said sensor comprises a photoelectricinfrared sensor.
 40. The system of claim 19, wherein said actuatorcomprises a pneumatic cylinder.
 41. The system of claim 19, wherein saidplate includes an upper section which applies pressure against the topof the rolled food item and a lower section which applies pressureagainst the bottom of the rolled food item.
 42. The system of claim 19,wherein said control circuit comprises a micro-controller.
 43. Thesystem of claim 19, wherein said control circuit activates said motor inresponse to said presence signal after a predetermined delay, saidpredetermined delay permitting the leading end of the supported foodstrip to enter said slot of said spool.
 44. The system of claim 43,wherein said predetermined delay comprises 100 ms when the supportedfood strip is being transported at about 35 feet per minute (fpm). 45.The system of claim 19, further comprising a vacuum system, wherein saidconveyor includes vacuum ports, and said supported strip of food isaligned on said conveyor with said vacuum system through said vacuumports.
 46. The system of claim 19, wherein the rolled food itemcomprises a dehydrated fruit product.
 47. The system of claim 19,wherein the trailing end of the supported food strip is adhered to therolled food item with a drop of an edible adhesive.
 48. A system forsimultaneously winding a plurality of supported strips of food into aplurality of rolled food items, each supported strip of food having aleading end and a trailing, comprising: an extruder configured todeposit a plurality of strips of food onto a plurality of supportstrips; a cutter to form a plurality of predetermined lengths of saidplurality of supported food strips; a conveyor to transport saidplurality of supported food strips; and a plurality of winding unitspositioned at an end of said conveyor and configured to receive theleading ends of respective plurality of predetermined lengths ofsupported food strips, each winding unit of said plurality of windingunits including: a motor having a shaft which rotates when said motor isactivated; a spool having a slot and coupled to said shaft of saidmotor, wherein said slotted spool rotates when said motor is activated;a guide positioned before said slot of said spool to direct the leadingend of the supported food strip into said slot; a sensor positionedabove said guide to detect the leading end and to generate a presencesignal in response thereto; an actuator with a displaceable member; aplate coupled to said displaceable member, said plate being positionedto permit said spool to rotate to form the rolled food item; and acontrol circuit associated with said motor, sensor, and actuator, saidcontrol circuit configured to activate said motor in response to saidpresence signal to rotate said slotted spool for a predetermined numberof degrees to form the rolled food item and, after said predeterminednumber of degrees, activate said actuator to displace said plate andeject the rolled food item from said slotted spool.
 49. The system ofclaim 48, wherein said conveyor is configured to transport between about1 and about 24 supported strips of food.
 50. The system of claim 48,wherein said plurality of winding units are arranged in a triangularconfiguration.
 51. The system of claim 50, wherein said plurality ofwinding units are arranged in an elevated triangular configuration. 52.The system of claim 48, wherein said plurality of winding units arearranged on one side of said conveyor.
 53. (Canceled).
 54. (Canceled).55. (Canceled).
 56. (Canceled).
 57. (Canceled).
 58. (Canceled). 59.(Canceled).
 60. (Canceled).
 61. (Canceled).